Unloading Knee Brace Apparatus

ABSTRACT

An adjustable tension knee brace for unloading weight from a knee joint afflicted with osteoarthritis, thus reducing pain and improving mobility, comprising: an upper and lower rigid posterior portion, anterior straps, and a tension adjustable geared hinge assembly. Four embodiments are disclosed of hinge assemblies useable with the knee brace, or other types of braces. The hinge assemblies comprise: two subunits housing intermeshed gears, and at least one elastic band extending between the hinge subunits over a cam surface above the gears. In three embodiments, U-shaped connectors secure the subunits and gears together, and the subunits may comprise a user mechanism that adjusts the elastic band&#39;s tension and thus the amount of weight unloaded, then releases it. Another embodiment comprises a core bracket to protect the band(s) and a mechanism to compress the elastic band at various points to increase the amount of tension, and with a quick release mechanism.

PRIORITY CLAIM

The present application is a divisional of and relies on the disclosuresof and claims priority to and the benefit of the filing date of U.S.patent application Ser. No. 15/585,968 filed May 3, 2017.

Further, the present application claims priority to and benefit fromU.S. Provisional Patent Application No. 62/331,315 filed on May 3, 2016.

The disclosures of each of the-above referenced applications areincorporated by reference herein in their entireties.

TRADEMARKS DISCLAIMER

The product names used in this document are for identification purposesonly. All trademarks and registered trademarks are the property of theirrespective owners.

FIELD OF THE INVENTION

The present invention disclosed herein relates generally to orthosisknee braces to relieve pain by unloading the joint by providingextension assistance and/or by redistributing the weight on the kneejoint.

BACKGROUND OF THE INVENTION

Osteoarthritis (OA) is a degenerative joint disease characterized bychronic deterioration of the joint cartilage and the underlying bone. Inparticular, the patellofemoral compartment is one of the most frequentpoints of knee pain. Unloading braces have been used as inexpensivetherapeutic solutions for knee OA; however, they are largely ineffectivein preventing and reducing pain. Therefore, the main aim of the variousembodiments of the present invention is to design an unloading kneebrace that reduces pain on a knee joint afflicted with OA.

Arthritis is currently the most common cause of disability among adultsin the United States. More than one hundred different rheumaticconditions fall under arthritis, the most common of which isosteoarthritis (OA), a degenerative joint disease marked by a chronicdeterioration of joint cartilage and the underlying bone. OA is one ofthe most common joint disorders in the United States, and the number ofthose afflicted is only projected to increase in the midst of an agingpopulation and increasing levels of obesity. Twenty-seven million adultsin the U.S. alone are affected by the disease. As the most typical typeof arthritis, the disorder has commonly affected the knee, and thepatellofemoral (PF) compartment within the knee joint in particular hasbeen one of the most frequent points of knee pain in the outpatientsetting. The PF compartment, seen in FIG. 1, performs a key role indaily movement and activity, enabling mobility over a large range ofmotion through flexion, extension, and rotation of its associatedcomponents. One of the most non-invasive and widely accepted methods forprevention of further deterioration of the articular cartilage withinthe knee joint is by using a knee brace. The joint itself, including itsunderlying cartilage, can only support a certain amount of force beforethe cartilage begins to wear away, and unloading knee braces decreasethe amount of force on the joint.

According to the American Academy of Orthopedic Surgeons and the U.S.Center for Disease Control and Prevention, nearly half of Americansdevelop symptoms due to knee OA by the age of 85, and the incidence ratefor PF pain syndrome has been reported to be approximately 22 adults forevery 1000 adults per year. In addition, up to 10 percent of the U.S.population suffers from pain and loss of function from patella arthritisand cartilage wear. The high prevalence of these injuries suggests thatthe condition affects a significantly large portion of the adultpopulation and will have a growing impact on healthcare systems in thefuture. On average, total knee arthroplasty, or knee replacementsurgery, costs between $10,000 and $30,000, and over 600,000 surgeriesare performed each year. Other surgical procedures such as articularcartilage restoration, osteotomy, and uni-compartmental kneereplacement, as well as corticosteroid and hyaluronic acid injections toreduce inflammation and absorb shock, respectively, are also veryexpensive. Thus, preventative treatments that reduce the amount ofstress, pressure, and invasive procedures on the knee are necessary forimproving the quality of life for patients and for reducing potentialmedical costs.

In addition, robust braces enable those with severe joint injuries toremain active when joint replacement is not appropriate. It is estimatedthat 27 million adults in the U.S. are suffering from osteoarthritis,and 454,652 patients with severe joint injuries and arthritis receivedknee replacement surgeries in 2004. Currently, nonpharmacologicalapproaches, such as physical therapy, and pharmacological methods areprimarily used to treat knee OA. When these are proven to beineffective, the treatment method culminates to surgery, and drawbacksinvolve internal joint bleeding, bone healing failure, nerve or tissuedamage, and infection. Thus, the development of a knee brace thatsignificantly unloads force on afflicted joints, prevents pain anddisability, and does not require many other treatments in conjunction isnecessary to address the challenges associated with establishing apurely non-pharmacological, orthotic approach to treating knee OA. Themain aim of the various embodiments of the prevent disclosure is todevelop a knee brace that significantly unloads force from thepatellofemoral compartment of a knee joint afflicted with osteoarthritisin order to relieve pain and disability.

OA Knee Braces

Osteoarthritic knee braces primarily comprise a rigid, or semi-rigid,frame with an upper frame member called an “upper cuff” situated acrossthe anterior thigh, and a “lower cuff” across the anterior or posteriortibia; and, straps that are on the opposing side of the cuffs to securethe frame onto the user's leg. The upper and lower cuffs are connectedby a rotary hinge assembly that pivots through a user's normal range ofmotion, or less depending on the injury.

In OA, the disease process includes degradative enzymes that erode thearticular cartridge, leading to bone-on-bone contact, which is theprimary source of the user's knee pain. OA knee braces classified as“unloading” braces pull the femur and tibia apart so that there is notbone-on-bone contact when the user is load bearing, such as walking,standing, exercising, etc. This is accomplished by the brace lifting thefemur, and/or pulling down the tibia, or otherwise keeping the femur andtibia condyles from making direct contact through the actions of theupper and lower cuffs locking the femur and tibia in positions relativeto the other.

Unloading knee braces may also comprise hinge assemblies that exert aforce in the medial to lateral direction to push the knee joint inward,thus separating the femur and tibia condyles—see FIG. 1. For example,there may be one hinge assembly in the brace, such as for a brace totreat OA in the left medial compartment with a hinge assembly on themedial side of the knee joint; or hinge assemblies on both sides. Thehinge assembly may comprise a component (e.g. an inflatable pad) thatpushes the knee joint laterally, e.g. inward and/or apart, to unloadforces on the medial side of the knee, and thus reduce the user's pain.

The hinges in unloading knee braces may also comprise components similarto a built-in breaking system where the user experiences an increase intension as the knee is bent to prevent the user's knee from collapsingwhile bending. The hinge assembly and cuffs engage in a majority of thework that the leg muscles would otherwise do to stabilize the knee jointthrough its entire range of motion.

More recently, a number of OA knee braces have been marketed toconsumers who wish to maintain an active life-style in spite of theirmedical condition. OA knee braces are now available that comprise hingeassemblies with the ability to exert forces to assist the user inmovement, otherwise known as “swing assistance” or “knee extensionassistance”. The hinge's exerted restoring forces can be counter to theuser's original direction of movement, such as propelling the user'sknee from a flexed to an extended position after the user has bent down.The hinge assemblies primarily comprise springs and/or elastic membersthat store potential energy when the user in bending their leg, such ascrouching down, during which the elastic members are stretched, or thesprings members are compressed or stretched. The restoring forcegenerated from the compression or stretching is used to assist the userwhen they move to extend their leg.

What is needed within the OA knee brace industry, though, is a kneebrace that effectively both unloads the user's weight off the kneejoint, and that provides stability to weakened muscles. It would also bebeneficial if the knee brace provides knee extension assistance to theactive user. There is also a need for an improved mechanism of unloadingthat does not require pushing the knee inward or otherwise realigningit, but instead relies upon a well-fitting rigid or semi-rigid frame andstraps, and/or hinge assemblies that are of an adjustable tension thatcan be activated by the user as needed, and of significantly highertension levels than the prior art's to engage in the mechanical workthat is normally done by the muscles of the knee while pulling thefemoral and tibia condyles apart.

SUMMARY OF THE INVENTION

Various embodiments of the present disclosure comprise a novel type ofunloading knee brace that has been designed to reduce the amount of painthat patients experience as a result of knee OA. The knee braces andhinge assemblies disclosed herein generate a force opposing the bendingor contracting/flexion of the knee joint. The braces can be suitable foreither a knee joint or elbow joint, however the knee joint will only bediscussed here in detail such that one of skill in the art could readilyapply this disclosure to an elbow brace. The brace effectively unloads asignificant amount of force within the knee by using a high-tensionresistance mechanism described herein, and by distributing the force toother areas of the body. This results in reduced friction in areas ofthe knee afflicted with OA, and therefore less pain. The embodimentsdescribed herein allow the user to: quickly (e.g. 1-3 seconds) engageand disengage tension in each joint mechanism as needed; adjust theamount of tension; and allow for tension to increase with increasingdegrees of flexion. The device is particularly suitable for peopleafflicted with patellofemoral osteoarthritis (OA), cartilage damage,meniscus damage, knee stability issues, and other types of kneeconditions for which pain intensifies during the bending or contractingof the knee, and for patients who lack the strength (e.g. quadricepsweakness) to extend their knees either during exercise or simple lifefunctions, such as standing from a seated position. The variousembodiments of the brace and hinge assemblies disclosed herein provideenhanced support for stabilizing the knee joint, and they can enhancethe user's normal physical or athletic performance by providingextension assistance.

Unloading Brace Vertical Support

The various embodiments of the present disclosure comprise a knee bracethat effectively unloads the user's weight off the knee joint via arigid or semi-rigid vertical support that covers the user's posteriorfemur and tibia, and with a pivoting hinge assembly connecting an upperand lower portion of the vertical support. The anterior side of thevertical support comprises at least one (e.g. one, two, or three) strapson the upper and on the lower portion.

It is noted that the vertical support of the present disclosure may alsobe used with a wide variety of types of hinge assemblies previouslyknown in the art for use by knee patients in order to effectively unloadweight from the knee joint.

The various embodiments of the knee brace further comprise a verticalsupport with an upper portion and a lower portion that are connected viaa hinge assembly on one side (for a medial or lateral brace), or via twohinge assemblies, one per side (for a full brace). Furthermore, thevertical support comprises an arcuate, curved, or semi-circular shapedrigid or semi-rigid unit posteriorly situated above and below the knee,and connected via a geared, pivoting hinge assembly. The upper and lowerportions may further comprise at least one strap on the anterior side tosecure the brace to the user's leg; and the upper portion may also havestraps and/or a mesh material anteriorly and/or posteriorly forsupporting the back of the thigh to effectively distribute force awayfrom the knee. The upper and lower portions may also be secured with ahook and loop type material, or a clip-type fastener or similar method.

The brace can be one-sided or bilateral (as in a right and left, ormedial and lateral support), the determination of which is based onwhether the knee is injured medially or laterally, or in the femoralcompartment, which is approximately central. The tensioned brace hingeassembly should be proximal to the injured part of the knee. A userbenefiting from a high-tension brace would ideally use a brace with bothlateral and medial side supports to generate torque on both sides. Theamount of torque can be modified by the strength of elastic materials,and the amount of torque may vary on each side to address the user'sspecific OA condition. The brace frames disclosed herein are especiallyable to target damage to the patellofemoral compartment; but other typesof knee injuries and medical conditions may benefit from only a sidesupport vertical member and/or one hinge assembly.

Brace Materials: The vertical support is made from rigid and/orsemi-rigid plastic, metal, other lightweight materials, such as carbonfiber or another suitable material that are mostly inelastic yetflexible, and are thus ideal to distribute weight-load knee forces.

Because the knee braces are subjected to high tension or high torquefrom the hinge assembly, then tight, form-fitting contact with the bodyis an important design feature. The brace may further comprise lightpadding lining the upper and lower portions, and/or the straps. The fitand material composition are designed to provide a high coefficient offriction between the brace and a user's leg so as to increase adhesionto the user's leg, and thus facilitate the transfer of weight-loadforces off the knee joint, while remaining comfortable to wear. Theupper and lower portions and/or straps can be contained or built withinan elastic sleeve to reduce the friction coefficient at the body/braceinterface. The fabrication method combined with using strong andlightweight materials will facilitate this design feature. Furthermore,the brace is preferentially made from common materials, such as braidedelastic bands, and is therefore less expensive and more accessible tousers that may not normally be able to afford a performance brace.

More specifically, the frame, or vertical support, comprises: an upperrigid, or semi-rigid, posterior portion sized to fit a user's posteriorfemur adjacent to and above a user's knee joint; a lower rigid, orsemi-rigid, posterior portion sized to fit a user's posterior tibiaadjacent to and below the user's knee joint; at least one latitudinalstrap (e.g. horizontal, diagonal, etc.) on the upper anterior side abovethe knee and extending between an upper portion medial side to a lateralside; and at least one latitudinal strap on the lower anterior sidebelow the knee and extending between a lower portion medial side to alateral side.

Size: The knee brace can be custom made for the user based on one ormore of: size, weight, level of physical activity of the user; weightand flexibility of the brace; etc. Or it can be sold over-the-counterbased on size (for example, small, medium or large), and/or by level oftension (low/medium/high). Or, the brace may be custom made to fit aparticular user—e.g. via digital imaging. In all situations, the bracemust be tight, form-fitting to the knee joint, lower femur, and toptibia, in order to effectively redistribute the load off of the kneejoint, and thus reduce a user's knee pain.

Hinge Assemblies

The present disclosure further comprises at least four differentembodiments of a pivoting hinge assembly, comprising at least oneelastic band (e.g. of moderate to high tension), and two intermeshed,teethed gears rotating in unison as the user flexes and extends theirknee.

These hinge assemblies can be used with the unloading brace verticalsupport disclosed herein; and/or with other knee braces well known inthe art.

In each of the disclosed hinge assemblies, the amount of tension forunloading can be adjusted by, for example: adding more elastic bands ofthe same or of different levels of tension; and/or diameter; and/or bysubstituting bands with different elastic properties—e.g. stiffer bandscreate more tension; and/or by moving a hinge component to fix one endand/or the center of an elastic band to prevent it from furtherextension—thus increasing the band's tension (e.g. see embodiments 2-4of the hinge assembly infra). The hinge assembly has smoothed sectionsto prevent the damage to the band(s), and to allow for smoothlydrawing-stretching-extending the bands over the hinge, whether or notthe band(s) come into contact with the rotating gears.

When more than one elastic band is used, the bands lie adjacentlongitudinally in the anterior side of the hinge assembly, and/or theposterior side, such as in parallel, or one atop the other, or othersimilar arrangements. Another design feature is that a plurality ofelastic bands improves safety of the brace by providing a backup supportin the unlikely that a band breaks or detaches.

Hinges with bands as large as one-half inch and as little as one-eightinch are envisioned, and larger and smaller bands could be used in thesame brace.

Elastic bands that exhibit different levels of tension comprisematerials, such as: real rubber, braid synthetic rubber cords, exoticelastic or other elastic materials. Braided bands offer more protectionto the elastic material, and other bands can use thin protective sheathsor a wet or dry lubricant to allow for smooth drawing over the hinge.

Holes: Other unique aspects of the hinge assemblies include the compactmethod of how elastic bands are connected to the brace, which maycomprise weaving through hole(s) in the geared components in the brace,hinge assembly—e.g. subunits, or hole(s) within the support structure.The hole(s) in the brace components are balanced to offer enoughstrength while minimizing the bulk and weight of the component. Strongermaterials can be used to allow for smaller sized brace components.

Another design feature includes using elastic bands that have a distinctending point that limits the degree of flexion based on the length ofthe elastic band and the length of the component, by limiting the amountof band drawn over a section of the hinge that acts as a cam unit, whichgenerates a mechanical advantage as it draws the elastic band(s) apartfrom its anchored ends. For example, in first embodiment, the bands arefixed at both ends; in second and fourth embodiment, the band(s) arefixed at the distal end only and are tension adjustable at the proximalend; and in third embodiment, the band(s) are fixed at both ends thatare both adjustable for tension.

The present disclosure further comprises multiple designs that supportup to four three-quarter inch bands across a single hinge, however, thishigh amount of resistance would be more applicable for braces thatresist mobility, e.g. immobilizing knee braces. High-tensionimmobilizing braces could allow a user or medical patient to move orexercise the joint safely by minimizing muscle engagement.

Another unique design feature associated with multiple elastic bands isthat bands can be mixed or combined with different strengths and sizesbased on the user's preferences, and different bands can be engaged atdifferent degrees of flexion. For example, one band could be engagedfrom 5-20 degrees of flexion, at which point another band would engage,doubling the resistance.

The elastic bands can be secured through a number of methods, includingthe use of clamps and pins through the elastic band, and designing thehole(s) in the brace and hinge assembly components that prevent the bandends from slipping out of hole(s) while the brace is under tension.Other band geometries can be used, such as circular bands that hook intothe top and bottom components of the brace and hinge assembly (e.g.within the subunits).

The distal and proximal hinge assemblies are preferentially fabricatedas a continuous material with the vertical support, or alternativelythey are secured to the brace vertical support (frame) by bolts, rivets,pins or something similar. A brace vertical support made of plastic orcarbon fiber would be shaped to include the hinge assemblies with theelastic bands and the gearing mechanism, either fabricated from the samematerial or a different material (e.g. a primarily metal hingeassembly).

The hinge assembly components on the lateral and medial side of the kneeare spaced snugly to keep a narrow profile. If multiple elasticmaterials are drawn across the hinge gears and cam units, they can beoriented vertically or horizontally to the desired dimensions of thebrace. The components can be symmetric or shaped to contour the leg.

The hinge assembly that connects the top and bottom components of thebrace can be a simple U-shaped joint or a larger component that willoffer additional lateral stability to the brace. These are threaded ordesigned in a way to minimize the size and profile, such as usingE-clips (circlips) or pressing the components in place.

The brace vertical support and hinge assemblies of the variousembodiment have few moving parts and are completely silent due to usingsoft and durable elastic bands.

Tension Adjustment and Engage/Disengage Features

Another unique feature of the brace design is that in second throughfourth embodiments, the user can either fully or partially disengage thetension mechanism. The tension engagement-disengagement feature allowsthe user to quickly increase the tension in the hinge assembly toprovide more stability and off-loading of their weight from their knee,such as when climbing stairs, and then to quickly turn-off the mechanismwhen it is no longer needed, such as at the top of the stairs, so thatthe user can more easily walk with a fuller range of motion.

User Unloading Mechanism: The tension, or counter-force, in the hingeassembly is adjustable by increasing the number of elastic bands toincrease the tension; and/or using elastic bands of more stiffness for ahigher tension; and/or by temporarily adjusting the tension by the useras needed via an unloading mechanism within the hinge assembly. In anembodiment (e.g. the first embodiment), the knee braces are manufacturedfor a specific tension (low, medium, and high) for a fixed tension orfixed range of tensions through the knee's range of motion. In anotherembodiment (i.e. second through fourth hinge assembly embodiment), thetension is easily adjustable by the user activating a hinge unloadingmechanism to allow the elastic band(s) to stretch to a point oftautness, and then deactivating the unloading mechanism when it is nolonger needed. The “temporary” user unloading mechanism can be locatedon either the proximal and/or distal end of the hinge assembly. Forexample, in second and fourth embodiment, the unloading mechanism can belocated on the proximal end on the user's thigh so they can easily reachit. And on the third embodiment, the unloading mechanism is located onboth or either the proximal and distal end, so the user can activate oneor both as needed, then release it.

Hinge Assembly—Embodiment 1- Fixed Tension

Hinge Assembly 1: In the first embodiment, the pivoting hinge assemblyas depicted in FIGS. 2-4 comprises: two opposing, facing subunits, e.g.substantially “C” shaped, with a proximal (top) and distal (bottom)short end, and an anterior (front) and posterior (rear) side. Eachsubunit houses one gear that intermeshes with the opposing gear duringarticulated joint movement, e.g. a proximal (first) gear, and distal(second) gear; at least one elastic band extending between the subunitson the anterior side of the gears and fixedly connected on the band'sends to or near the posterior side of the subunits; and a U-shapedconnector on the medial and lateral side pinning the subunits togetherwhile allowing the gears to rotate.

The subunits may further comprise cam units, e.g. located within thesubunits as carved or molded into the internal housing of the subunitsand residing slightly above-anteriorly- to the gears so that the elasticbands are drawn over the cams and the gears. The cam units increase thetension in the elastic bands with increasing degrees of flexion.

Hinge Assembly—Embodiment 2—Adjustable Tension—via Rotating Handle andSlider

Hinge Assembly 2: The various embodiments of the present disclosurefurther comprise a second embodiment of a hinge assembly as depicted inFIGS. 5A-7 for use in a knee brace as disclosed herein, or other kneebrace for treating a medical condition that requires unloading of theknee joint. The hinge assembly of second embodiment is similar to thefirst embodiment comprising the subunits with opposing intermeshed gearsand cam units, but with the addition of a housing unit attachedproximally to the proximal subunit. The housing unit comprises arotatable handle attached to a slide mechanism that enables the user toquickly adjust the tension on one end (e.g. the proximal end) of theelastic band(s) by pulling the band(s) proximally—e.g. upward.

More specifically, the band(s) proximal end is attached to a slidemember that moves vertically (i.e. proximally-distally) to pull the bandtaut to increase its tension. For example, when a user rotates a handlethat is located on the lateral and/or medial side of the proximal end ofthe hinge assembly, above the knee, it forces a connecting slide memberto move up-proximally, thus stretching the proximal end of the band(s).Thus, the user can easily increase the stability and stiffness of thebrace by rotating the hinge handle.

Thus, the second hinge assembly embodiment comprises: a slide memberattached to the proximal end of the elastic band, and a rotatable handleon an exterior surface of the hinge assembly, that is able to move theslide member and the elastic band proximal end upward upon a userrotating the handle, thereby increasing tension in the elastic band; andthat is able to release or lower the tension when the handle iscounter-rotated, and wherein the handle is able to be rotated to aplurality of positions that produce different levels of tension (e.g.the handle has various tension settings).

Hinge Assembly—Embodiment 3—Adjustable Tension via Ratchet-Pawl

Hinge Assembly 3: In the third embodiment, the hinge assembly asdepicted in FIGS. 8-10 comprises a substantially rectangular shapedhousing with a curved anterior side, that is divided into two opposing,but spaced apart subunits. Each subunit houses one gear that intermesheswith the opposing gear during articulated joint movement, e.g. aproximal (first) gear, and distal (second) gear; and at least oneelastic band extending between and within the subunits on the anteriorside of the gears and fixedly connected on the band's ends to or nearthe posterior side of the subunits. A core bracket member covers theelastic band between the subunits' open space to protect the band(s),and to pin the gears together while continuing to allow them to rotate.

The third embodiment further comprises a rotatable ratchet-pawl systemon the proximal and/or distal end of the hinge assembly to adjust theamount of stretching, or tension, in the band. The user can rotate todifferent positions to pull the band(s) tighter while reducing theireffective length. For example, rotating the ratchet-pawl system inwardtowards the bracket member increases the tension in the hinge assembly,making it less flexible, thus off-loading more of the user's weight fromthe knee joint, and providing more stability. The user can then quicklyrelease the ratchet-pawl system by pulling on a deactivation lever thatis co-located with the systems.

Thus, the hinge assembly of the third embodiment comprises: a rotatableratchet-pawl system on a distal and/or a proximal end of the hingeassembly, able to anchor the elastic bands to the rotating member, whichupon rotation draws tension in the band; and a disengagement member thatis able to quickly release the ratchet-pawl system to reduce or releasethe band tension.

Hinge Assembly—Embodiment 4—Adjustable Tension—Spooled Wire

Hinge Assembly 4: The various embodiments of the present disclosurefurther comprise a fourth embodiment of a hinge assembly as depicted inFIGS. 11-13 for use in a knee brace as disclosed herein, or other kneebrace for treating a medical condition that requires unloading of theknee joint. The hinge assembly of embodiment 4 is similar to embodiment1, 2 with similar subunits, opposing gears with cam units, and twoU-shaped connector brackets. But, the fourth embodiment comprises one ormore strands of elastic bands with the band's ends fixed in the distalsubunit while the band(s) proximal end (or midpoint if the band iffolded in half) is pulled on by a wire that is rolled on a spool

Thus, in the fourth embodiment, the second embodiment's backward movinghandle and vertical sliding member, are replaced with a rotatable knobconnected to a spool of wire that pulls on the proximal end of theelastic band as the user rotates the knob. The knob is rotatable to fixpositions so the user is able to adjust the tension in the band to thedesired level, and release the tension by rotating the knob in theopposite direction. More turns on the knob will result in higher tensionin the elastic band, and more off-loading of forces on the user's kneejoint. The knob mechanism can alternatively rely on friction between theknob and hinge subunit to keep sustain tension, or via a ratchet-pawlsystem connected internally to the knob, or via known methods, such asfastening dials such as the Boa® system that can be used in place of thecurrent design.

Furthermore, in the fourth embodiment, the hinge assembly furthercomprises an unloading mechanism to enable a user to quickly engage anddisengage, and/or increase and decrease the tension in the elasticband(s). The elastic band is connected on a band ends to the distalsubunit, and the unloading mechanism comprises: an inelastic line orwire, with a distal and a proximal end, attached to the elastic band onthe distal end, and to a pulley on a spool on the proximal end; a spooloperatively connected to an external rotatable knob; wherein the user isable to increase the tension in the elastic band by rotating the knob,whereby the line or wire is fixed to the pulley, and wound around thespool by the pulley; and, the user is able to decrease the tension byrotating the knob in the opposite direction, or by releasing aratchet-pawl system or a locking flange washer system operativelyconnected to the knob.

Method of Use—Embodiments 1-4

The knee brace and/or hinge assemblies disclosed herein are able toreduce load bearing via: reducing the weight, forces, and/or pressure ona knee joint when a user is load bearing on their legs, such asstanding. And/or, the knee brace and hinge assemblies are able toprovide knee extension assistance when walking, bending, moving fromsitting to standing, exercising, etc.; therefore, the user has to exertless physical effort to move their knee between flexion and extension.

In an embodiment, the method of use for reducing load bearing on theknee joint comprises the steps of: attaching a knee brace of the firstembodiment to a user's pain afflicted knee, comprising laying the insidesurface of the brace vertical support comprising the upper and lowerportions against the back-posterior side- of a user's leg; and closingthe brace straps on the front-anterior side- of the user's leg, such astwo straps around the user's anterior femur and two strap's around theuser's anterior tibia; and, load bearing on the user's knee joint,wherein the load and/or pressure on the knee joint is reduced to theextent that the user experiences a reduction in pain as compared to loadbearing without the knee brace.

The method of use further or alternatively comprises extensionassistance, with the steps of: bending of the user's knee, wherein thehinge elastic band stretches and generates a counter or restoring forceto propel the hinge back from a bent, flexed position to a straight,extended position; wherein the brace reduces the amount of forcerequired to be exerted by the user's leg and knee muscles to return thebrace hinge to an extended position from a bent position; and whereinthe load and/or pressure on the user's knee joint is reduced to theextent that the user experiences a reduction in pain as compared toflexing and extending the user's knee without a knee brace.

And as stated supra, for the second through fourth embodiments of thehinge assembly, the method of use further comprises temporarilyincreasing and increasing the brace tension, as needed by the user,wherein: the user quickly activating a hinge unloading mechanism to pullone end of the elastic band(s) taut to increase tension and stability inthe hinge assembly, and then to deactivate the mechanism when it is nolonger needed. Various embodiments of the hinge mechanism comprise: arotatable handle attached to a sliding member, wherein rotating thehandle causes the sliding member to move vertically while pulling oneend of the elastic band(s) taut (second embodiment); a rotatableratchet-pawl system on one or both ends of the hinge assembly that auser can easily move clockwise or counterclockwise to impinge theelastic band(s) and increase tension therein, then release (thirdembodiment); and a rotatable knob connected to an internally housedspool of rigid line or wire that is attached to the center of a foldedelastic band, wherein turning the knob pulls on the elastic band toincrease the band's tension, and rotating the knob in the oppositedirection releases the tension (fourth embodiment).

Method of Making

The various embodiments of the present disclosure may use traditionalmanufacturing processes for knee braces, and/or 3D printing to produceprototypes of the components (such as the gears and/or subunits of thehinge assembly) to then be injection molded to produce a subunitcomprising a gear and a cam unit that is one-piece.

The fabrication technique of these braces has allowed the braces to havefeatures that were technically very difficult to create in the priorart—e.g. subunits comprising gears and cam units that are one piece.Therefore, a better fitting brace that is higher functioning and morecomfortable is possible. 3D printing and injection molding ofsemi-flexible materials are key attributes for this. These fabricationmethods and materials can also keep production costs low thereby helpingmore people with osteoarthritis.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other features, aspects, and advantages of the presentinvention will become better understood with regard to the followingdescription, appended claims, and accompanying drawings as follows.

FIG. 1 is an illustration of the anatomy of a human knee joint.

FIGS. 2-4 comprise illustrations of the vertical support with the hingeassembly of the first embodiment.

FIG. 2 is an illustration of an anterior left perspective view of theknee brace of the present disclosure in an extended position, with ahinge assembly of the first embodiment.

FIG. 3 is an illustration of a right-side view of the knee brace in anextended position.

FIG. 4 is an illustration of an anterior right perspective view of theknee brace in a flexed position.

FIGS. 5A-7 comprise various views of the hinge assembly of the secondembodiment.

FIG. 5A is an illustration of a top perspective view of the hingeassembly of the second embodiment comprising a lever to adjust thetension within one elastic band.

FIG. 5B is an illustration of a top perspective view of the hingeassembly of the second embodiment comprising a lever to adjust thetension within two parallel elastic bands.

FIG. 6 is an illustration of a side view of the hinge assembly of thesecond embodiment.

FIG. 7 is an exploded view of the hinge assembly of the secondembodiment.

FIGS. 8-10 comprise various views of the hinge assembly of the thirdembodiment.

FIG. 8 is an illustration of an outer side view of the hinge assembly ofthe third embodiment comprising a lever and cap to enable the user toadjust the tension in the elastic cable.

FIG. 9 is an exploded view of the hinge assembly of the thirdembodiment.

FIG. 10 is an illustration of the hinge assembly of the third embodimentwithin the OA knee brace of the present disclosure.

FIGS. 11-13 comprise various views of the hinge assembly of the fourthembodiment.

FIG. 11 is an illustration of a top perspective view of the hingeassembly of the further embodiment comprising a knob to adjust thetension within one folded elastic band that is pulled by a wire on aspool.

FIG. 12 is an illustration of a side view of the hinge assembly of thefourth embodiment.

FIG. 13 is an illustration of an exploded view of the hinge assembly ofthe fourth embodiment.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

As used herein, the term “proximal” is synonymous with top or upper, asin above the knee, or the side closest to the user's torso. Likewise,the term “distal” is synonymous with bottom or lower, as in below theknee, or the side furthest from the user's torso.

As used herein, the term “anterior” refers to the front of the kneeand/or brace, and “posterior” the back. As seen in the figures when thehinge in oriented up-down, anterior is upward, and posterior isdownward.

Throughout the following detailed description the same reference numbersrefer to the same elements in all of the figures.

Knee Brace Vertical Support

Table 1, infra, lists the components illustrated in FIGS. 2-4 for theknee brace frame 10 and hinge assembly embodiment (1). The knee brace 10comprises a knee brace frame, or vertical support, and a geared pivotinghinge assembly. As illustrated in FIGS. 2-4, the vertical supportcomprises: an upper (proximal) rigid, or semi-rigid, posterior portion12, and a lower (distal) rigid, or semi-rigid, posterior portion 14. Asubstantially long oval, or rectangular shaped cutout 16 resides in thecenter of portion 12 and 14 for comfort. Both portions 12 and 14 fitsnuggly to the backside, or posterior surface, of a user's leg justabove and below their knee. In an embodiment, knee brace 10 is sizedsmall, medium, or large, depending upon the outer circumference of theuser's thigh. The knee brace can also be custom fitted. Normally, thediameter and circumference of the upper portion 12 is larger than thatof the lower portion 14.

Straps: The vertical support further comprises on the front, anteriorside, of knee brace 10, at least one horizontal strap 18 above and belowthe knee to secure the brace tightly to the user's leg. In theembodiments illustrated in FIGS. 2-4, two straps 18 extend horizontallybetween the medial and lateral sides of the brace 10. Therefore, twostraps 18 extend horizontally on the anterior side of the brace 10between the brace upper portion 12′s medial and lateral side, and twostrap 18 extend horizontally between the brace lower cuff 14′s medialand lateral side, for a total of four straps per knee brace 10.

The ends of the strap 18 comprise a fixation member 20 to secure theends of the straps in an overlapping manner such that the strap end(s)lie flat on the user's leg, and do not dangle or hang free. Fixationmembers 20 comprise materials commonly known, such as: Velcro-likematerial; buckles; and so forth.

TABLE 1 Knee Brace 10 FIG. Item # Component Name 12 Upper rigid orsemi-rigid cuff or portion 14 Lower rigid or semi-rigid cuff or portion16 Cutout centered in cuffs/portions 12, 14 18 Brace anterior straps 20Strap end fixation members- e.g. Velcro

Hinge Assemblies—4 Embodiments

The present disclosure comprises at least four different pivoting hingeassemblies, each comprising at least one elastic band 26, and two gearedteeth, intermeshed (28 p, 28 d). Each type of hinge assembly can be usedto generate tension in a one-sided brace (hinge medial or lateral side)or a full knee brace (hinge medial and lateral sides). The variousembodiments of the hinge assembly disclosed herein comprise: a hingeassembly 22 (embodiment 1), 23 (embodiment 2), 38 (embodiment 3), or 40(embodiment 4), in which each is connected on the hinge assemblyproximal end to the brace upper portion 12, and the hinge assemblydistal end to the lower portion 14, or in a similar manner to a varietyof knee braces known in the prior art for unloading weight from the kneejoint.

The two opposing gears (or gear wheels 28 p, 28 d) of the hinge assembly22, 23, 38, 40 are connected using a support bracket or member thatcomprises: 2 opposing U-shaped connectors 30 (embodiments 1, 2, 4), likea “floating support member”; or via a center core bracket (FIGS. 8-10,part 50) with openings (embodiment 3). The hinge assemblies have acenter axis which is attached to either the center cap 50 or theU-shaped support members, or brackets, 30 to allow for rotation aroundthe gears while generating tension (or a breaking force, or acounter-restorative force), thus allowing the wearer of the brace tomore easily flex and extend. The U-shaped connectors are operativelypositioned medially and laterally to the subunits, and are able tofunction to: pin the subunits together while enabling the gears torotate in unison; protect the gears and elastic band; and limit amaximum degree of flexion of the hinge assembly.

The hinge assembly incorporates at least one band of high-strengthelastic material that is attached to both the proximal and distalsubunits of the hinge assembly. The elastic band stores energy when itis drawn across the hinge upon knee flexion by the wearer of the kneebrace. The elastic bands are ported through holes in the hinges orsupport members and are fixed in place by using over-bore clamps. Forexample, the elastic band(s) are anchored within and to the proximal anddistal subunits via the use of clamps or “hog rings” on the elasticbands and holes through which the bands are threaded, and are drawnapart over the gears upon increasing flexion and gear articulation.

The subunits may further comprise cam units, e.g. located within thesubunits as carved or molded surfaces into the internal housing of thesubunits and residing slightly above-anteriorly- to the gears so thatthe elastic bands are drawn over the cams and the gears (e.g. FIGS. 7and 13 internal curve in subunit 24 d, 24 p). The cam units increase thetension in the elastic bands with increasing degrees of flexion of theuser's knee. The cam geometry is variable and designed to generate aforce that corresponds to unloading requirements.

The subunits further provide a mechanism to limit the maximum extensionof the elastic bands and hinge assembly to prevent hyperextension of theknee. The subunits will not permit the gears to continue to rotate oncethe subunits 24 p, 24 d make full contact (e.g. FIG. 5A, where theanterior side of subunits fit together at top of “C”). The surface anglebetween the subunits' point of contact is a design variable that can bemodified to satisfy user requirements.

Alternate designs are based on the needs of the user and include one ormultiple elastic bands within the hinge assembly on either or both themedial or lateral side of the knee brace. These alternate designs alsoinclude bands of varying sizes that generate different amounts ofresistance. Using more than one band can be tailored to engage andincrease in tension as the degree of flexion is increased.

The elastic bands generate a significant amount of resistance thatopposes flexion, thereby reducing the amount of force in the knee jointand the amount of friction in areas afflicted with OA.

Hinge Assembly 22—Embodiment 1—Fixed Tension

Hinge Assembly 22- Embodiment (1) 24p Hinge proximal subunit 24d Hingedistal subunit 26 Elastic band member 28p Gear within proximal subunit28d Gear within distal subunit 30 Bracket (U-shaped connector)-2 32pScrew securing 30 proximal end 32d Screw securing 30 distal end

In the first embodiment, the pivoting hinge assembly 22 as depicted inFIGS. 2-4 comprises: two opposing subunits, 24 p proximal-top and 24 ddistal-bottom. In the embodiment exemplified in FIGS. 2-4, the subunitsare substantially “C”-shaped, but other shapes are envisioned within thescope this disclosure. Each subunit possesses a proximal (top) anddistal (bottom) end, and an anterior end (front side showing the elasticband 26) and posterior side (rear side showing the gears 28 p, 28 d).Each subunit houses one toothed gear 28 p or 28 d that intermeshes withthe opposing oothed gear during articulated joint movement. For example,gear 28 p proximal is housed within 24 p subunit, and intermeshes withgear 28 d distal that is housed within 24 d subunit. Furthermore, atleast one elastic band member 26 extends between and within the subunitson the anterior (or posterior) side of the gears and is fixedlyconnected on the band's ends to the posterior side (or anterior) (inhinge 22, 38), or one end is fixed proximally (in hinge 23, 40) of thesubunits. Alternative points of fixation of the band's ends areenvisioned within the scope of the present disclosure.

And, at least one elastic band integrated within the proximal and distalhinge subunits is able to increase a tension force within the elasticband when acted upon by the hinge assembly, thereby reducing load forceson a user's knee. The elastic band(s) are anchored above and below thehinge, and are drawn apart upon increasing flexion and geararticulation. The surface of the hinge component on which the elasticband(s) is(are) drawn over is designed as a mechanical cam, whichcompounds the tension in the band upon increasing degrees of flexion.The cam geometry is variable and designed to generate a force thatcorresponds to unloading requirements.

A stop in maximum extension is provided by the upper and lower hingecomponents 24 making full contact. The surface angle is a designvariable that can be modified to satisfy user requirements.

If more than one elastic band member is used, it is alignedlatitudinally (e.g. in parallel, above/below, etc.) with the first bandmember 26, and it is need not be of the same size (e.g. diameter) or thesame tension. Elastic bands 26 are normally installed by themanufacturer in this embodiment, so a knee brace ordered using hingeassembly 22 has a fixed tension strength to off load weight and/or toprovide a restorative force. But, in the hinge assemblies 23, 38, 40 ofthe second through fourth embodiments, the user also has the ability toadjust the tension quickly using a built-in user mechanism comprising: arotating handle 34 (in hinge 23); and/or two ratchet-pawl systems 48 p,48 d (in hinge 38); and/or a rotatable knob 46 (in hinge 40) thatdepresses-compresses and/or pulls taut the elastic bands 26, and thusincreasing the tension in the band(s) 26. This provides an off-loadingforce to re-distribute the user's weight off of their knee joint, and/oris generates a breaking force if the user is squatting down, thusproviding stability and preventing the user from having to exert moreforce to move up/down. When the user returns to standing up and movingagain, then they can release the tension on the band(s) 26 viamechanisms built into each of the hinge assembly embodiments to allowtheir knee a more relaxed range of motion.

The hinge assembly 22 further comprises two curved or U-shaped connectorbrackets 30 that are attached directly to the gears 28 p, 28 d (throughthe subunits 24 p, 24 d) on the medial and lateral sides, via screws 32p proximal and 32 d distal. U-connector brackets 30 hold the gears andsubunits together while allowing the gears to rotate with their gearteeth intermeshing as the user flexes and extends their knee.

Hinge Assembly 23—Embodiment 2—Adjustable Tension—via Rotating Handle

The various embodiments of the present disclosure further comprise asecond embodiment, i.e. hinge assembly 23 as depicted in FIGS. 5A-7 foruse in a knee brace as disclosed herein, or in another knee brace knownin the industry for treating OA or otherwise unloading of the kneejoint. The hinge assembly 23 of second embodiment is similar to hingeassembly 22 of the first embodiment, but with the addition of a rotatinghandle 34 that enables the user to easily and temporarily adjust thetension on the elastic band(s) by rotating clockwise or counterclockwiseto push a connected slide member 36 and its attached proximal end of theelastic band upward, and then rotating in the opposite direction toreturn the slider member and elastic band to their original position.FIGS. 5A, 6, and 7 illustrates a hinge assembly 23 with one elastic band26, and FIG. 5B illustrates a hinge assembly 23 with two parallelelastic bands 26 that provide enhanced tension to the brace.Additionally, FIG. 7 is an exploded view to illustrate the innercomponents of the hinge assembly.

Table 2, infra, lists the components illustrated in FIGS. 5A-7 for thehinge assembly 23 embodiment (2).

TABLE 2 Hinge Assembly 23- Embodiment (2) 24p Hinge proximal subunitconnected to 25 24d Hinge distal subunit 25 Housing for Rotatable Handleand Slide Member 26c Elastic band member- at center 26p Elastic bandmember- proximal end connected to 36 26d Elastic band member- distal end28p Gear within proximal subunit 28d Gear within distal subunit 30Bracket (U-shaped connector)-2 32p Screw securing 30 proximal end 32dScrew securing 30 distal end 34 Handle to adjust tension 36 Slide member

In hinge assembly 23, as compared to 22, the point of fixation of theproximal end of the elastic band(2) 26 p in not in the bottom-posteriorside of the subunit 24 p. Rather band end 26 p is fixedly connected tohandle slide member 36, which moves vertically (i.e.proximally-distally) to pull the band 26 taut (increasing tension) whenhandle 34 is rotated (clockwise/counterclockwise) by the user. Thelonger portion of handle 34 engages more tension in the band than theshorter ends of the handle. Thus, the user can easily increase thestability and stiffness of the hinge by rotating handle 34 to positionthe handle slide member 36 further away from the hinge, such as whenthey are about to bend over, and then release handle 34 to release thetension when they are about to walk again. Increased tension providesmore off-loading of the user's weight from the knee joint.

Additionally, handle 34 has multiple settings, which gradually mayincrease tension, or remove it completely.

Hinge Assembly 38—Embodiment 3—Adjustable Tension via Ratchet-Pawl

Table 3, infra, lists the components illustrated in FIGS. 8-10 for thehinge assembly embodiment (3).

TABLE 3 Hinge Assembly 38- Embodiment (3) 40p Hinge proximal subunit 40dHinge distal subunit 42c Elastic band member- at center 42p Elastic bandmember- proximal end 42d Elastic band member- distal end 44p Gear withinproximal subunit 44d Gear within distal subunit 46p Screw securing Gear44p through 50 46d Screw securing Gear 44d through 50 48p RotatableRatchet proximal member to adjust tension 48d Rotatable Ratchet distalmember to adjust tension 50 Core bracket- elastic band cover, and/orbreaking mechanism 52p Screw securing 48p, 54p to 40p 52d Screw securing48d, 54d to 40d 54p Disengagement member to release 48p 54dDisengagement member to release 48d 56p Band ridge lines for 48p 56dBand ridge lines for 48d

Hinge Assembly 3: In the third embodiment, the hinge assembly 38 asdepicted in FIGS. 8-10 comprises a substantially rectangular shapedhousing, with a curved anterior side, that is divided into two spacedapart subunits—40 p proximal, and 40 d distal. Each subunit houses a camunit and one toothed gear that intermeshes with the opposing gear duringarticulated joint movement, e.g. a 44 p proximal and 44 d distal; and atleast one ridged elastic band 42 (e.g. one, two, or three parallelbands) extends between the subunits on the anterior side of the gearsand is fixedly connected on the band's ends to the posterior side of thesubunits near the band's 42 p and 42 d ends.

A core bracket member 50 covers the elastic band(s) at its center point42 c, which is equal distance between the open space that separatessubunits 40 p, 40 d. In the exemplified embodiment of FIGS. 8-10, corebracket 50 is a curved member, covering the anterior-top half of thehinge assembly.

Core bracket 50 is fixed to the gear 44 p via screw 46 p and to gear 44d via screw 46 d, and in a manner that does not impede rotation of thegears, while anchoring the proximal gear and subunit to the distal gearand subunit. Core bracket 50 also functions to protect the elastic bandfrom being impinged by outside objects.

Core bracket 50 may also provide as an anchor to support the elasticband 42 c to prevent it from moving, and thereby fixing the elastic bandfrom which it can be drawn, in both directions. The elastic band isdrawn from as the hinge rotates with increasing degrees of flexion. Theband or bands may or may not be fixed to core bracket 50. When fixed inplace, a ring clamp is used to secure the bands in a groove feature orby other means inside of core bracket 50.

The third embodiment may further comprise on the proximal and/or distalend of each hinge assembly 38, a ratchet-pawl system comprising arotatable ratchet member 48 p, 48 d to block the elastic band fromstretching, thus increasing the tension in the band. Rotatable ratchetmember-systems 48 p, 48 d can be rotated through different positions bythe user to adjust the tension in the elastic band(s). For example, bandends 46 p, 46 d may comprise ridge lines 56 p, 56 d that the ratchetmember 48 p, 48 d can be locked down at. Thus, the user is able toquickly adjust the level of tension in the band(s) by engaging member 48p and/or 48 d at any time—. e.g. upward rotation of 48 p (clockwise asshown in FIG. 8) increases the force that member 48 p applies to theelastic band at 42 p, thus increasing the tension. Then disengagementmember 54 p and/or 54 d are pressed by the user to completely disengagethe ratchet 48 p and/or 48 d from the band to reduce the tension, aswhen the user is walking, running, etc.

Screw 52 p is used to secure ratchet 48, pin 50, and the base of gear 44p to the subunit 40 p. Likewise, screw 52 d is used to secure subunit 40d to the base of gear 44 d.

Hinge Assembly 40—Embodiment 4—Locking Knob with Spooled Wire

As illustrated in FIGS. 11-13, the fourth embodiment is similar to thefirst and second embodiment by comprising: “C-shaped” subunits, opposinggears with cam units, and two U-shaped connector brackets pinning thegears together while allowing them to freely rotate. The fourthembodiment further comprises a tension adjustable mechanism, with: anexterior rotating knob, that may be user position adjustable with aninternal ratchet-pawl system connected to the knob internal surface; anda single elastic band that is folded at the band's center (or a singleshorter band unfolded), and a wire attached to the band center (or bandproximal end) and to a pulley on a spool and the spool is connected tothe knob and/or its ratchet-pawl system. The knob mechanism canalternatively rely on friction between the locking flange washer, theknob, and the hinge subunit to sustain tension. Commercially availablefastening dials such as the Boa® system can be used in place of thecurrent design. The user is able to increase the tension in the elasticband by rotating the knob, whereby the wire is wound around the spool bythe pulley; and, the user is able to decrease the tension by rotatingthe knob in the opposite direction.

The wire can comprise either a metal or fabric/polymer material, such asnylon. Variations in this design using either one or more elastic bandsmay use a clamp to secure the line or wire to the elastic band(s), andthe other bands will anchor to the opposing hinge component.

Table 4, infra, lists the components illustrated in FIGS. 11-13 for thehinge assembly embodiment (4).

TABLE 4 Hinge Assembly 40- Embodiment (4) 24p Hinge proximal subunitconnected to 54 24d Hinge distal subunit 26c Elastic band member- atcenter 26p Elastic band member- proximal end connected to 44 26d Elasticband member- distal end 28p Gear within proximal subunit 28d Gear withindistal subunit 30 Bracket (U-shaped connector)-2 32p Screw securing 30proximal end 32d Screw securing 30 distal end 44 Wire connected ondistal end to 26c 46 Outer knob 48 Locking flange washer 50 Spool 52Pulley connected to wire 44 54 Housing for Spool-Pulley

As illustrated in FIGS. 11-13, the fourth embodiment comprises, arotating knob 46 that is turned by the user to draw tension in theelastic band 26, which is fastened to an inelastic wire 44 or line byuse of a clamp or tie (not shown) at the band's midpoint 26 c. Wire 44is also bent in half (or is a single short wire) and both wire ends areconnected to a pulley 52 that is on spool 50, which upon the rotation ofknob 46-winds wire 44 around the pulley 52-spool 50, thereby increasingtension in the elastic band 26.

Knob 46 is held in place by friction between the locking flange washer48, the knob 46, and the housing 54 so that the user can lock the band26 at a specific tension, then release it by rotation. The locking knoballows the user to adjust the tension in the band(s) to the desiredlevel. More turns on the knob will result in higher tension in theelastic bands.

Method of Making

The various embodiments of the present disclosure may use traditionalmanufacturing processes for knee braces 10, and/or 3D printing toproduce prototypes of the components (such as the gears and/or subunitsof the hinge assembly) to then be injection molded. In an embodiment,the brace is sized to fit the user snugly and can be form fitted to theuser. Unique fabrication methods and materials make this form fittingbrace possible. For example, based on used fabrication methods,two-dimensional pictures can be used to generate a model that contoursthe user's leg, and the material properties of this material will have aslight amount of flexibility in the lateral direction, and minimalflexibility in the direction of extension.

The fabrication technique of these braces has allowed the braces to havefeatures that were technically very difficult to create in the priorart—e.g. subunits comprising gears and cam units that are one piece.Therefore, a better fitting brace that is higher functioning (e.g. forsports activity) and more comfortable is possible. 3D printing andinjection molding of semi-flexible materials are key attributes forthis. These fabrication methods and materials can also keep productioncosts low thereby helping more people with osteoarthritis.

In an embodiment, 3D printing provides the ability to produce thesubunits as one piece comprising the gear and cam unit, and made ofdurable plastic. It also allows for customizing the degree and distancebetween the cam unit and gears to adjust the amount of draw in theelastic bands; and to adjust the angle of contact between the subunitsanterior surface to control the range of motion of the knee brace.

Unloading and Torque

The knee brace vertical support of the present disclosure differs fromthe prior art in that it unloads a significant amount of force that isnormally applied within the knee. The basis for patellofemoral pain isthat a large amount of force is distributed over a small area. Injuriesto this surface can result in severe pain and defects/injuries, and thecartilage surface can degrade, thus exposing bone and nerves in anaccelerated time frame. The tension-generating, unloading mechanisms inthe present disclosure's knee brace primarily distributes forcesexperienced in the knee to other body parts and dampens impact thatwould be painful to a joint afflicted with osteoarthritis. The effect ofaction of the brace is equivalent to a significant reduction of weightby the user. The most fundamental treatment for sufferers ofosteoarthritis is weight loss.

From a design perspective, the amount of force unloaded in the kneebraces of the present disclosure are characterized by their relativetorque measured about the hinge assembly (in units of inch-pounds[in-lbs.]), and the amount of weight unloaded or offset (in units ofpounds [lbs.]). For example, the general strength or tension of the kneebraces of the present disclosure are generally broken down into threecategories:

Low: below 3 lbs. unloaded

Medium: range of 3-15 lbs. unloaded

High: above 15 lbs. unloaded

The reduced force in an OA afflicted knee joint via use of the presentbrace and/or hinge assemblies allows for deeper flexion of the user'sknee that would normally be prohibited due to pain. This deeper flexionengages the user's quadriceps to an extent that would normally beavoided by the user due to debilitating pain, thus facilitating a usergaining strength through exercise. Additionally, the resistancegenerated by the brace can strengthen supporting muscle and soft tissueduring exercise, for example the hamstring can be strengthened via abrace vertical support and/or hinge assembly as disclosed herein thatresists tension on the quadriceps.

Method of Use—Embodiments 1-4

In the various embodiments of the present disclosure, the amount ofweight unloading (or resistance or tension generated in the brace) canreadily be tailored to the user based on their size, weight, and desiredathletic performance. Braces based on this concept have promise of beinglightweight, robust, of a narrow side profile, and well-fitting tousers. Unlike braces in the prior art, those disclosed herein can benarrow and lightweight to be worn under clothing, which is usually notpossible for athletic performance braces. For these reasons, the bracecan be ideal for a range of injury types and severity.

The various embodiments of the knee brace of the present disclosure canbe used, by way of non-limiting examples: prophylactically to preventinjury; to reduce joint pain (e.g. during physical exercise or athleticcompetition); to rehabilitate existing injuries; post-operatively (hightension braces to immobilize the joint to a comfortable level); asextension assist device for medical conditions such as osteoarthritis,with some stability support for proper knee alignment through the rangeof motion.

Likewise, the knee brace 10 and/or hinge assemblies 22, 23, 38, and 40disclosed herein are able to: reduce the weight, forces, and/or pressureon a knee joint when a user is load bearing on their legs, such asstanding. And/or, the knee brace and hinge assemblies are able toprovide knee extension assistance when walking, bending, moving fromsitting to standing, exercising, etc.; therefore, the user has to exertless physical effort to move their knee between flexion and extension.

In an embodiment, the method of use for reducing load bearing on theknee joint comprises the steps of: attaching a knee brace 10 of with thehinge assembly 22, 23, 38 or 40 to a user's pain afflicted knee,comprising laying the inside surface of the brace vertical supportcomprising the upper 12 and lower 14 portions against the back-posteriorside- of a user's leg; and closing the brace straps 18 on thefront-anterior side- of the user's leg, such as two straps around theuser's anterior femur and two strap's 18 around the user's anteriortibia; securing the straps with Velcro-like members 20; and, loadbearing on the user's knee joint, wherein the load and/or pressure onthe knee joint is reduced to the extent that the user experiences areduction in pain as compared to load bearing without the knee brace.

The method of use further or alternatively comprises extensionassistance, with the steps of: bending of the user's knee, wherein thehinge elastic 26 or 42 band stretches and generates a counter orrestoring force to propel the hinge back from a bent, flexed position toa straight, extended position; wherein the brace 10 reduces the amountof force required to be exerted by the user's leg and knee muscles toreturn the brace hinge assembly 22, 23, 38, and 40 to an extendedposition from a bent position; and wherein the load and/or pressure onthe user's knee joint is reduced to the extent that the user experiencesa reduction in pain as compared to flexing and extending the user's kneewithout a knee brace.

While the hinge assembly 22 of the first embodiment provides a constant,fixed level of tension, or range of tensions, the hinge assemblies ofthe other embodiments have unloading mechanisms that can be quicklyactivated and deactivated by the user. Thus, for the second throughfourth embodiments of the hinge assembly 23, 38, and 40, the method ofuse further comprises temporary method(s) for the user to adjust thetension- as needed, comprising: the user quickly activating a hingeunloading mechanism to pull one end of the elastic band(s) taut toincrease tension and stability in the hinge assembly, and then todeactivate the mechanism when it is no longer needed. Variousembodiments of the hinge mechanism comprise: a rotatable handle attachedto a sliding member, wherein rotating the handle causes the slidingmember to move vertically while pulling one end of the elastic band(s)taut (second embodiment); a rotatable ratchet-pawl system on one or bothends of the hinge assembly that a user can easily move clockwise orcounterclockwise to impinge the elastic band(s) and increase tensiontherein, then release (third embodiment); and a rotatable knob connectedto an internally housed spool of rigid line or wire that is attached tothe center of a folded elastic band, wherein turning the knob pulls onthe elastic band to increase the band's tension, and rotating the knobin the opposite direction releases the tension (fourth embodiment).

Conclusion

Although the above-recited examples are not to be construed as limitingthe scope of the various embodiments of the present disclosure, theexamples indicate that the knee brace and hinge assemblies can beconstructed for use in an elbow brace. It is apparent that the skilledartisan can modify the dimensions of the brace and hinge assemblies totreat pain and inflammation associated with a variety of elbowdisorders.

It is also readily apparent that the range of adjustability of thebraces within the scope of the present invention inter alia by selectingmaterials of different elasticity for construction of the arm members,by selecting different longitudinal or cross-sectional dimensions forthe arm members, or by selecting pads of different fixed thicknesses ordifferent ranges of adjustable thicknesses.

It is further evident that although the knee brace and hinge assembliesof the present invention have only been described above in terms of afew embodiments adapted to treat osteoarthritis, it is apparent to theskilled artisan that these embodiments are readily adaptable totreatment of pain associated with a variety of knee disorders. Forexample, additional embodiments envisioned with the scope of the presentdisclosure comprise hinge assemblies with the user tension adjustmenthandle, knob, etc. on the user's tibia versus the exemplified embodimenton the user's femur.

It is also apparent that the skilled artisan could easily modify thedimensions, materials, number and type of elastic bands, and so forth toachieve an equivalent level of pain relief as the embodiments disclosedherein.

Although various features of the invention may be described in thecontext of a single embodiment, the features may also be providedseparately or in any suitable combination. Conversely, although theinvention may be described herein in the context of separate embodimentsfor clarity, the invention may also be implemented in a singleembodiment.

As used herein, the term “about” refers to plus or minus 5 units (e.g.percentage) of the stated value.

Reference in the specification to “some embodiments”, “an embodiment”,“one embodiment” or “other embodiments” means that a particular feature,structure, or characteristic described in connection with theembodiments is included in at least some embodiments, but notnecessarily all embodiments, of the inventions.

As used herein, the term “substantial” and “substantially” refers towhat is easily recognizable to one of ordinary skill in the art.

It is to be understood that the phraseology and terminology employedherein is not to be construed as limiting and are for descriptivepurpose only.

It is to be understood that the details set forth herein do not construea limitation to an application of the invention.

Furthermore, it is to be understood that the invention can be carriedout or practiced in various ways and that the invention can beimplemented in embodiments other than the ones outlined in thedescription above.

It is to be understood that the terms “including”, “comprising”,“consisting” and grammatical variants thereof do not preclude theaddition of one or more components, features, steps, or integers orgroups thereof and that the terms are to be construed as specifyingcomponents, features, steps or integers.

What is claimed is:
 1. An unloading knee brace comprising, a. a verticalsupport comprising an upper portion and a lower portion with a medialand a lateral side, wherein the upper portion comprises, an upper rigidor semi-rigid posterior curved unit sized to fit a user's posteriorfemur adjacent to and above a user's knee joint; at least onelatitudinal strap extending anteriorly between an upper portion medialside to a lateral side; wherein the lower portion comprises, a lowerrigid or semi-rigid posterior curved unit sized to fit a user'sposterior tibia adjacent to and below the user's knee joint; at leastone latitudinal strap extending anteriorly between a lower portionmedial side to a lateral side; b. at least one pivoting hinge assembly,wherein a hinge assembly proximal end is connected to the upper portionand a hinge assembly distal end is connected to the lower portion; c.wherein the pivoting hinge assembly further comprises, a proximal and adistal subunit with a posterior and anterior side, each subunit housinga gear that intermeshes with the opposing gear during articulated jointmovement; d. at least one elastic band integrated within and extendingbetween the proximal and distal hinge subunits, and able to increase atension force within the elastic band when the hinge assembly is movedto a flexed position, thereby reducing a load force on a user's knee; e.wherein when the knee brace is a one-sided brace, then the hingeassembly is on the lateral or the medial side of the knee; and, when theknee brace is a full brace, then the hinge assembly in on the lateraland on medial side of the knee; f. wherein the at least one elastic bandof the hinge assembly further comprises, the band(s) extending betweenthe subunits on an anterior side of the gears, and wherein when there ismore than one elastic band, the elastic bands lie touching in adjacent,longitudinal orientations; g. wherein the hinge assembly furthercomprises an unloading mechanism to enable a user to quickly engage anddisengage, and/or increase and decrease the tension in the elasticband(s); and h. wherein the unloading mechanism comprises, a slidemember attached to the proximal end of the elastic band, and a rotatablehandle on an exterior surface of the hinge assembly, able to move theslide member and the elastic band proximal end upward upon a userrotating the handle either clockwise or counter-clockwise, therebyincreasing tension in the elastic band; and able to release the tensionwhen the handle is counter-rotated, wherein the handle is able to berotated to a plurality of positions that produce different levels oftension.
 2. An unloading knee brace comprising, a. a vertical supportcomprising an upper portion and a lower portion with a medial and alateral side, wherein the upper portion comprises, an upper rigid orsemi-rigid posterior curved unit sized to fit a user's posterior femuradjacent to and above a user's knee joint; at least one latitudinalstrap extending anteriorly between an upper portion medial side to alateral side; wherein the lower portion comprises, a lower rigid orsemi-rigid posterior curved unit sized to fit a user's posterior tibiaadjacent to and below the user's knee joint; at least one latitudinalstrap extending anteriorly between a lower portion medial side to alateral side; b. at least one pivoting hinge assembly, wherein a hingeassembly proximal end is connected to the upper portion and a hingeassembly distal end is connected to the lower portion; c. wherein thepivoting hinge assembly further comprises, a proximal and a distalsubunit with a posterior and anterior side, each subunit housing a gearthat intermeshes with the opposing gear during articulated jointmovement; d. at least one elastic band integrated within and extendingbetween the proximal and distal hinge subunits, and able to increase atension force within the elastic band when the hinge assembly is movedto a flexed position, thereby reducing a load force on a user's knee; e.wherein when the knee brace is a one-sided brace, then the hingeassembly is on the lateral or the medial side of the knee; and, when theknee brace is a full brace, then the hinge assembly in on the lateraland on medial side of the knee; f. wherein the at least one elastic bandof the hinge assembly further comprises, the band(s) extending betweenthe subunits on an anterior side of the gears, and wherein when there ismore than one elastic band, the elastic bands lie touching in adjacent,longitudinal orientations; g. wherein the hinge assembly furthercomprises an unloading mechanism to enable a user to quickly engage anddisengage, and/or increase and decrease the tension in the elasticband(s); h. a rotatable ratchet-pawl system on a distal and/or aproximal end of the hinge assembly, able to anchor the elastic bands tothe rotating member, which upon rotation draws tension in the band; andi. a disengagement member able to quickly release the ratchet-pawlsystem to reduce or release the band tension.
 3. A method of unloadingforces from a knee by a user of a knee brace, the steps comprising, a.attaching a knee brace with a pivoting hinge assembly to a user's knee,wherein the pivoting hinge assembly comprises, a proximal and a distalsubunit, each subunit housing a gear; a distal and a proximal teethedgear, with an anterior and a posterior gear side, and able to intermeshduring an articulated joint movement; at least one elastic band with aproximal band end and a distal band end, wherein the elastic bandextends between and within the subunits on an anterior side of thegears, with the distal band end affixed to the distal subunit; anadjustable unloading mechanism to increase the tension on the elasticband; b. activating the unloading mechanism when the user requiresincreased stability and/or tension in the knee brace, wherein the userexperiences a reduction in a knee pain; and, c. deactivating theunloading mechanism when the user no longer requires the increasedstability and/or tension; and d. wherein the unloading mechanism furthercomprises, a slide member attached to the proximal end of the elasticband, and a rotatable handle on an exterior surface of the hingeassembly, that is able to move the slide member and the elastic bandproximal end upward upon a user rotating the handle, thereby increasingtension in the elastic band; and able to release or lower the tensionwhen the handle is counter-rotated, and wherein the handle is able to berotated to a plurality of positions that produce different levels oftension.